Method for Producing an Abrasion-Resistant Wood Composite Board, and Production Line Therefor

ABSTRACT

A method for producing an abrasion-resistant wood-based panel with a top side and a bottom side. At least one decorative layer, in particular as a printed decoration, is provided on the top side. The method includes applying at least one first resin layer to the at least one decorative layer on the top side of the wood-based panel, uniformly scattering abrasion-resistant particles onto the first resin layer on the top side of the wood-based panel. The first resin layer on the top side of the wood-based panel provided with the abrasion-resistant particles is not dried after application. The method also includes applying at least one second resin layer to the first, moist resin layer provided with the abrasion-resistant particles on the top side of the wood-based panel, and then drying the assembly of first resin layer and second resin layer on the top side of the wood-based panel in at least one drying apparatus.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. application Ser. No.16/761,937 filed on May 6, 2020, which is the United States nationalphase of International Application No. PCT/EP2018/080152 filed Nov. 5,2018, and claims priority to European Patent Application No. 17 200109.1 filed Nov. 6, 2017, the disclosures of which are herebyincorporated by reference in their entireties.

BACKGROUND OF THE INVENTION Field of the Invention

The present invention concerns a method for producing anabrasion-resistant wood-based panel provided with a decorative layer anda production line for carrying out this method.

Description of Related Art

A large number of products or product surfaces that are subject to wearand tear due to mechanical stress must be protected from prematuredamage or destruction due to wear and tear by applying wear-resistantcoatings. These products can be furniture, interior finishing panels,floors, etc.

Depending on the frequency and strength of use, different protectivemeasures must be applied to guarantee the user the longest possibleservice life.

A large number of the above mentioned products have decorative surfacesthat quickly become unsightly and/or difficult to clean when worn due tointensive use. These decorative surfaces very often consist of papersimpregnated with duroplastic resins, which are pressed onto thewood-based substrates used in so-called short-cycle presses.Melamine-formaldehyde resin is very often used as the thermosettingresin.

One approach to improve the wear resistance of decorative surfacesconsists in the application or introduction of abrasion-resistantparticles into the resin layers close to the surface. This can be done,for example, by applying a liquid resin containing abrasion-resistantparticles to the corresponding surfaces, whereby in the case ofdecorative wood-based panels, corundum particles are usually used asabrasion-resistant particles. When applying corundum-containing melamineresin, however, it has been shown that problems due to sedimentationoccur due to the differences in density between the melamine resin andthe corundum. This leads to sedimentation in preparation tanks, pumps,pipelines and the roller application units. Therefore, on the one hand,the entire area must often be cleaned to remove the deposits and, on theother hand, a higher corundum application rate must be used to achieve acertain wear value. In addition, the aforementioned sedimentation leadsto inhomogeneities in the application units, which must also becompensated for by higher dosing. A further serious disadvantage of thistechnology is that the corundum-containing resin formulations causeconsiderable wear on all plant components that come into contact withthe resin formulation. The higher dosage in combination with thesedimentation problems in turn leads to poorer transparency at higherwear classes. This is particularly noticeable with dark decors.

In order to avoid sedimentation of the corundum particles in the liquidresin and the problems associated with this, another approach toapplying the abrasion-resistant particles is to scatter them onto astill liquid resin layer applied to the wood-based panel using asuitable device. Here it is apparent that the corundum particles do notimmediately and completely penetrate into the resin layer, but liepartially loose on top of each other. The loose corundum particles canbe blown off by subsequent air currents, as in the case of a downstreamcirculating air dryer, which dries the moist melamine resin layer,whereby this corundum is lost to its intended function (abrasion) andinstead leads to wear in downstream plant components, such as the dryer.

This results in various disadvantages for production. For example, ithas been observed that electrostatic charging of the corundum particlesprevents the formation of a homogeneous scattering curtain. Furthermore,the whirling in the convection dryer leads to a loss of corundum andrequires an increased amount of corundum; the dryer is contaminated bythe corundum; rapid wear of the transport chains in the dryer bycorundum; i.e. overall increased material costs due to corundum loss andchain wear. In addition, the strong air flow in the dryer causes adistribution of the fine corundum in the production hall, whichrepresents a health hazard for the employees present. Productiondowntime can also be caused by contamination of the optical sensors ofthe plant by corundum dust.

SUMMARY OF THE INVENTION

The present invention is therefore based on the technical object ofavoiding and improving the above mentioned disadvantages of the previousapproach to scattering abrasion-resistant particles on wood-based panelscoated with liquid resin.

According to the invention, the set object is solved by a process withthe features described in the present application and a production linewith the features described in the present application.

Accordingly, a process for the production of an abrasion-resistantwood-based panel with an top side and an bottom side is provided,wherein at least one decorative layer, in particular as a printeddecoration, is provided on the top side, and wherein a protective layerof a not yet completely cured formaldehyde resin is applied to thedecorative layer, which comprises the following steps:

-   -   applying at least one first resin layer to the at least one        decorative layer on the top side of the wood-based panel,        wherein the wood-based panel provided with the protective layer        and decorative layer is not heated in a dryer before the        application of the first resin layer,    -   even scattering of abrasion-resistant particles on the first        resin layer on the top side of the wood-based panel,    -   wherein the first resin layer on the top side of the wood-based        panel provided with the abrasion-resistant particles is not        dried after application, and    -   applying at least a second layer of resin to the first, (still)        moist resin layer on the top side of the wood-based panel, which        is provided with the abrasion-resistant particles,    -   subsequent drying of the structure consisting of the first resin        layer and the second resin layer on the top side of the        wood-based panel in at least one drying device.

The present process therefore enables the provision of wood-based panelswith a decorative layer in various formats with high wear resistance ina cost-effective manner. According to the present process, a first resinlayer, in particular in the form of a first thermosetting resin layer,such as a melamine-formaldehyde resin layer, is applied to thedecorative layer (pretreated or non-pretreated) of the wood-based panel.The first resin layer is not initially dried or partially dried, butrather the abrasion-resistant particles are evenly scattered onto thewet or still liquid first resin layer on the top side of the wood-basedpanel using a suitable scattering device. Since the first resin layer isstill liquid at the time of scattering, the abrasion-resistant particlescan sink into the resin layer. Subsequently (i.e. without intermediatedrying of the first resin layer with the abrasion-resistant particlesscattered thereon) a second resin layer is applied to the still moistfirst resin layer. This is done by installing an additional applicationunit directly behind the scattering device (i.e. between the first dryerand the scattering device). With its roller application, the additionalapplicator takes up the abrasion-resistant particles that are not fixedon the first resin layer or have not penetrated the first resin layerand transports them back to the resin applicator. There a compensatingconcentration is set and the removed abrasion-resistant particles areevenly applied to the next surfaces via the roller. This results in anenrichment of the abrasion-resistant particles in the second applicationunit up to a content of abrasion-resistant particles of max. 10%. Inaddition to preventing loose particles from being blown away orabsorbed, this also reduces or even largely eliminates the adverseeffect of corundum particles protruding from the coated surface on asubsequent press plate, for example.

With the present process, a reduction in the consumption ofabrasion-resistant material is possible, as there is no loss ofabrasion-resistant particles such as corundum in the dryer. At the sametime, a reduction in dust pollution of the environment and the obvioushealth hazard for employees; as well as corundum dust deposits on plantcomponents of the production line is achieved. A significant advantageis also the reduction of corundum deposits on the transport chains, thussaving additional material costs by replacing the chains. In addition,the service life of the press plates in the downstream pressing processfor laminate formation is increased. Overall, the process costs arereduced due to lower material and maintenance costs. Furthermore, no newdevices/equipment have to be installed in the production line.

According to the invention, the wood-based panel provided with thedecorative layer is not heated in a dryer, such as an IR dryer, beforethe first resin layer is applied. This can be done by switching off anIR dryer provided in the production line or by not having an IR dryer inthe production line. By avoiding the heating of the wood-based panelwith a decorative layer, no electrostatic charging of the panel surfaceoccurs and the scattering curtain becomes homogeneous when scatteringthe corundum.

It is not obvious for an expert to dispense with heating the printedwood-based panel in an IR dryer, since a protective layer of resin istypically applied to the decorative layers applied by direct printing.The protective layer may be a formaldehyde-containing resin, inparticular a melamine-formaldehyde resin, urea-formaldehyde resin ormelamine-urea-formaldehyde resin, and may contain glass spheres (size50-150μ) as spacers for intermediate storage of the boards. Thisprotective layer serves as a temporary protection of the decorativelayer for storage before further finishing. The protective layer on thedecorative layer is not yet fully cured, but has a certain residualmoisture content of approx. 10%, preferably approx. 6%, and can becrosslinked even further. Such protective layers are described, forexample, in WO 2010/112125 A1 or EP 2 774 770 B1.

The typical step of heating decorative layers provided with such athermosetting protective layer is to dry the protective layer and toadjust the residual moisture level and thus the stickiness of theprotective layer and the adhesion of subsequent resin layers.

In the case of the present method, however, it has been shown that thestep of heating the protective layer has a negative effect on thescattering pattern of the abrasion-resistant particles. Omitting theheating of the printed wood-based panel provided with a protective layercauses a homogenisation of the scatter pattern and thus an evendistribution of the abrasion-resistant particles on the panel surface.

The resin layers used in the present process are preferably based onaqueous formaldehyde-containing resins, especially melamine-formaldehyderesin, urea-formaldehyde resin or melamine-urea-formaldehyde resin.

From WO 2007/042258 A1, a process for the production ofabrasion-resistant boards with a decorative surface andabrasion-resistant particles scattered thereon is known, in which an HDFboard is printed after appropriate pretreatment (primer, base coat) in agravure printing process and the printed motif is dried, but the lacquersystem used differs substantially from the aqueous resin system used inaccordance with the invention.

For example, in WO 2007/042258 A1 an acrylate-containing polyester resin(LaromerUP35D) is applied as a base coat with a quantity of 20-50 g/m².Corundum particles or aluminium oxide particles are sprinkled onto thenot yet cured lacquer. A top coat is then applied to the wet base coatwith the scattered abrasion-resistant particles. A radiation-curableacrylic resin (Laromer LR8987) is used as the base resin for the topcoat. After application of the first coat of paint, it is not at leastpartially cured or gelled to fix the lacquer. This procedure is known toa specialist for lacquer systems containing acrylate. Such lacquersystems are mixed with reactive thinner and photoinitiators forprocessing, which serves to adjust the viscosity, surface properties anddegree of cross-linking of the cured paint. During the curing process,the reactive thinner is incorporated 100% into the lacquer, so that theamount applied is also the amount that remains on the plate. Drying toremove a solvent is therefore not necessary either before or afterapplying the coating. On the contrary, heating before and/or after thevarnish application could lead to undesired evaporation of the reactivethinner, which is irritating like the acrylic varnish systems; theapplication of heat must be avoided accordingly during processing.

In contrast to the lacquer systems of WO 2007/042258 A1, aqueous resinsystems, especially aqueous formaldehyde-containing resin systems, areused in the present process. These aqueous resin systems have to bedried in the manufacturing process. For polymerization bypolycondensation and from this a final product can be produced.Accordingly, it is not obvious to dispense with one or more heating ordrying steps in a process for the production of refined wood-basedpanels in which aqueous resin systems are applied.

The first layer of resin is applied in a variant of the process in anamount between 10-100 g/m², preferably 40-80 g/m², especially preferably45-60 g/m². The first resin layer is applied, for example, with agrooved application roller in a first application unit. The solidscontent of the first resin layer is between 50-70% by weight, preferably50-60% by weight, especially preferably 55% by weight. The layerthickness of the first resin layer applied to the decorative layer isbetween 10 and 100 μm, preferably between 40 and 80 μm, especiallypreferably between 45 and 60 μm.

In a further version of the present process, particles of corundum(aluminium oxides), boron carbides, silicon dioxides, silicon carbidesare used as abrasion-resistant particles. Corundum particles areparticularly preferred. These are preferably white high-grade corundumwith a high transparency, so that the optical effect of the underlyingdecoration is affected as little as possible. Corundum has an unevenspatial shape.

The amount of scattered abrasion-resistant particles is 10 to 50 g/m²,preferably 10 to 30 g/m², especially preferably 15 to 25 g/m². Thequantity of abrasion-resistant particles scattered depends on theabrasion class to be achieved. For example, the quantity ofabrasion-resistant particles scattered ranges between 10 to 15 g/m² inthe case of abrasion class AC3, between 15 to 20 g/m² in abrasion classAC4 and between 20 to 25 g/m² in abrasion class AC5. In the presentcase, the finished panels preferably have abrasion class AC4.

Abrasion-resistant particles with grain sizes in the classes F180 toF240, preferably F200, are used. The grain size of class F180 covers arange of 53-90 μm, F220 of 45-75 μm, F230 34-82 μm, F240 28-70 μm (FEPAstandard). In one variant, white fused alumina F180 to F240 are used asabrasion-resistant particles, preferably in a main particle size rangeof 53-90 μm. In a particularly preferred version, class F200 corundumparticles are used, where F200 is a mixture between F180 and F220 andhas a diameter between 53 and 75 μm.

The abrasion-resistant particles must not be too fine-grained (risk ofdust formation), but also not too coarse-grained. The size of theabrasion-resistant particles is therefore a compromise. Overall,however, the corundum particles should be larger than the entire toplayer to provide abrasion resistance.

Silanized corundum particles can be used in a more advanced form.Typical silanizing agents are aminosilanes.

In a further variant of the present method, the resin to be applied asthe first resin layer on top of the wood-based panel may contain fibres,in particular wood fibres or cellulose fibres. The application rate ofthe fibres, such as cellulose fibres, when applied together with thefirst resin layer, is between 0.1-0.5 g/m², preferably 0.2-0.4 g/m²,particularly preferably 0.25 g/m². The addition of fibres such ascellulose fibres to the first layer contributes to increasing theviscosity of the resin liquor and thus to an increased application ofthe first top layer to the wood-based panel.

In a further version of the present process, the second resin layer tobe applied to the top of the wood-based panel is applied in an amount ofbetween 10-50 g/m², preferably 20-30 g/m², in particular preferably20-25 g/m². Overall, the amount of the second resin layer is less thanthe amount of the first resin layer.

The total amount of the first and second resin layer is between 50-100g/m², preferably 60-80 g/m², especially preferably 70 g/m². Thus, in onevariant, the amount of the first resin layer is 50 g/m² and the amountof the second resin layer is 25 g/m².

As already mentioned above, an accumulation of abrasion-resistantparticles in the second resin layer occurs due to the entrainment ofloose particles by the second coating unit. Thus, the resin to beapplied as the second resin layer may contain 5 to 15 wt %, preferably10 wt %, of abrasion-resistant particles.

In another version, the at least one wood-based panel is a mediumdensity fibreboard (MDF), high density fibreboard (HDF) or coarseparticle board (OSB) or plywood and/or a wood-plastic panel.

In one version, a resin layer is also applied to the bottom side of thewood-based panel parallel to the second resin layer on the top side ofthe panel. The amount of resin layer applied to the bottom side of thewood-based panel can be between 50-100 g/m², preferably 60-80 g/m², andespecially preferably 60 g/m². Preferably, the lower resin layer (e.g.brownish) is coloured to simulate a countermove.

The solids content of the resin used for the top and bottom side is50-70% by weight for both the top and bottom side, preferably 50-60% byweight, and in particular preferably 55% by weight.

The second resin layer is preferably applied parallel or simultaneouslyto the top and bottom side of the wood-based panel in at least onedouble application device (roller application unit). After applicationof the second resin layer, drying (air drying) of the structureconsisting of first and second resin layer takes place in a first dryingdevice. Accordingly, at least one resin layer is applied to the bottomside of the wood-based panel together with the second resin layer to beapplied to the top side of the panel.

The resin layer(s) applied to the bottom side act as a countermove.Applying the resin layers to the top side and bottom side of thewood-based panels in approximately equal quantities ensures that thetensile forces on the wood-based panel caused by the layers appliedduring pressing cancel each other out. The counter-tension applied tothe bottom side corresponds in the layer structure and the respectivelayer thickness approximately to the layer sequence applied to the topside with the difference of the abrasion-resistant particles and glassbeads as explained in detail below.

In a further embodiment of the present method, at least one furtherresin layer, preferably a third, fourth, fifth, sixth and seventh resinlayer, is applied to the dried structure consisting of the first andsecond resin layer provided with the abrasion-resistant particles on thetop side of the wood-based panel and dried after each application.

It is also preferred that the other resin layers include glass beadsand/or fibres, especially wood fibres or cellulose fibres.

This allows a third resin layer to be applied in parallel to the top andbottom sides of the wood-based panel, i.e. to the respective dried resinstructure. In the case of the top side, this would be the resinstructure consisting of the first and second resin layer including theabrasion-resistant particles and in the case of the bottom side, thiswould be a resin layer.

The amount of the third resin layer applied to the top side of thewood-based panel can be between 10-50 g/m², preferably 20-30 g/m²,especially preferably 25 g/m².

The amount of resin layer applied in parallel to the bottom side of thewood-based panel can be between 30-80 g/m², preferably 40-60 g/m², andespecially preferably 50 g/m².

The solid content of the resin used for the third resin layer is 50-70wt % for both the top and bottom side, preferably 50-60 wt %, especiallypreferably 55 wt %.

In a further embodiment of the present method, at least a fourth layerof resin is applied to the top and parallel to the bottom of thewood-based panel.

The amount of the fourth resin layer applied to the top side of thewood-based panel can be between 10-40 g/m², preferably 15-30 g/m², inparticular preferably 20 g/m², with a solids content of between 50-80 wt%, preferably 60-70 wt %, in particular preferably 60-65 wt %, e.g. 61.5wt %.

In one variant, the resin to be applied as a fourth resin layer to thetop of the wood-based panel may contain glass beads, with the glassbeads preferably acting as spacers. The preferred glass beads have adiameter of 50-100 μm, preferably 60-80 μm. The application rate of theglass beads, when applied together with the third resin layer, is 1-5g/m², preferably 2-4 g/m², especially preferably 3 g/m².

In another variant, the glass beads can be sprinkled onto the fourthresin layer applied to the top of the wood-based panel. In this case,i.e. when the glass beads are scattered, the application rate of theglass beads is 5-10 g/m², preferably 6-8 g/m², especially preferably 6g/m².

The amount of resin layer applied in parallel to the bottom side of thewood-based panel can be between 20-70 g/m², preferably 30-50 g/m²,especially preferably 40 g/m² with a solids content of 50-70 wt %,preferably 50-60 wt %, especially preferably 55 wt %.

It is also advantageous if the resin layer applied to the top side andbottom side of the wood-based panel is dried in at least one dryingdevice.

Following the drying process for the fourth top resin layer and parallellower resin layer, it is optionally possible to apply at least one fifthresin layer each to the top side and bottom side of the wood-basedpanel.

The amount of the fifth resin layer applied to the top side of thewood-based panel can be between 10-40 g/m², preferably 15-30 g/m²,especially preferably 20 g/m² at a solids content of 50-80 wt %,preferably 60-70 wt %, especially preferably 60-65 wt %, e.g. 61.6 wt %.

In a further variant of the present method, the resin to be applied as afifth resin layer on the top of the wood-based panel may contain glassbeads. If glass beads are added to the resin to be applied, the amountof glass beads applied is 1-5 g/m², preferably 2-4 g/m², especiallypreferably 3 g/m².

The amount of resin layer applied in parallel to the bottom side of thewood-based panel can be between 10-60 g/m², preferably 20-50 g/m², inparticular preferably 30 g/m² with a solids content of 50-70 wt %,preferably 50-60 wt %, in particular preferably 55 wt %.

In an even more advanced variant of the present process, a sixth and aseventh resin layer are applied to the top side and the complementaryresin layers to the bottom side of the wood-based panel. The sixth andseventh resin layers applied to the top surface may also contain fibresor glass beads.

It should also be noted that additives such as hardeners, wettingagents, defoamers, release agents and/or other components can be addedto all resin layers.

The sixth and seventh resin layers (as final layers) applied to the topside and bottom side of the wood-based panel are each dried in at leastone further drying device assigned to the respective coating unit. Thedrying of the respective resin layers is preferably carried out to aresidual moisture of 6-9% by weight, e.g. in a circulating air dryer.

In the pressing step following the last drying step, the layer structureis pressed under the influence of pressure and temperature in ashort-cycle press at temperatures between 150 and 250° C., preferablybetween 180 and 230° C., especially preferably at 200° C. and a pressurebetween 100 and 1000 N/cm², preferably 300 and 700 N/cm², especiallypreferably between 400 and 600 N/cm².

The decorative layer mentioned above can be applied by direct printing.In the case of direct printing, a water-based pigmented printing ink isapplied by gravure or digital printing, whereby the water-basedpigmented printing ink can be applied in more than one layer, e.g. inthe form of two to ten layers, preferably three to eight layers.

In the case of direct printing, the application of at least onedecorative layer is carried out as mentioned above by means of ananalogue gravure and/or digital printing process. The cravure printingprocess is a printing technique in which the elements to be depicted arepresent as depressions in a printing form which is inked beforeprinting. The printing ink is mainly located in the depressions and istransferred to the object to be printed, such as a wood fibre carrierboard, due to the contact pressure of the printing forme and adhesiveforces. In digital printing, on the other hand, the print image istransferred directly from a computer to a printing machine, such as alaser printer or inkjet printer. This eliminates the need for a staticprinting form. In both processes, the use of aqueous inks and inks orUV-based colouring agents is possible. It is also conceivable to combinethe above-mentioned printing techniques from gravure and digitalprinting. A suitable combination of the printing techniques can becarried out directly on the carrier plate or the layer to be printed oreven before printing by adapting the electronic data sets used.

It is also possible that there is at least one base coat layer betweenthe wood-based panel or carrier board and the at least one decorativelayer.

The base coat layer preferably used for this purpose comprises acomposition of casein as binder and inorganic pigments, in particularinorganic colour pigments. White pigments such as titanium dioxide canbe used as colour pigments in the base coat layer or other colourpigments such as calcium carbonate, barium sulphate or barium carbonate.In addition to the colour pigments and casein, the base coat layer mayalso contain water as a solvent. It is also preferred if the pigmentedbase coat layer applied consists of at least one, preferably at leasttwo, in particular preferably at least four successive layers or coats,where the quantity applied between the layers or coats may be the sameor different.

The present method thus enables the production of an abrasion-resistantwood-based panel with a decorative layer and a resin structure withabrasion-resistant particles. The wood-based panel provided with adecorative layer comprises a resin structure of first and second resinlayers on the top side, each containing abrasion-resistant particles, acorresponding resin layer on the bottom side, at least one third resinlayer on the top side and a corresponding resin layer on the bottom sideof the wood-based panel, at least one fourth, fifth, sixth and seventhresin layer on the top side and resin layers each corresponding theretoon the bottom side of the wooden material panel, wherein glass beads maybe contained in each of the fourth to seventh resin layers provided onthe top side of the wooden material panel.

In a preferred design, the present process enables the production of anabrasion-resistant wood-based panel with the following layer structure(seen from bottom to top): Counteracting layer consisting of six resinlayers—wood-based panel—base coat layer—print decorationlayer—protective layer, in particular a protective layer of a not yetcompletely cured resin—first resin layer with cellulose fibres—layer ofabrasion-resistant particles—second resin layer—third resin layer—fourthresin layer with glass beads—fifth resin layer with glass beads—sixthresin layer with glass beads—seventh resin layer with glass beads.

The protective layer serves to cover the decor and protect the decorduring intermediate storage (stacking, storage, transport). The otherresin layers on the top side together form an overlay that protects thefinished laminate against abrasion.

The production line for carrying out the present process comprises thefollowing elements:

-   -   at least a first application device for applying a first layer        of resin to the top surface of the wood-based panel,    -   at least one device arranged downstream of the first application        device in the processing direction for scattering a        predetermined quantity of abrasion-resistant particles;    -   at least one second application device arranged behind the first        application device and scattering device in the processing        direction for applying a second resin layer to the top side of        the wood-based panel,    -   at least one first drying device arranged downstream of the        second application device in the processing direction for drying        the layered structure of first and second resin layers.

In a preferred variant of the present production line, no drying deviceis provided before the first application device or, if a drying deviceis installed as part of the production line, this drying device is notin operation, i.e. not active.

There is also no drying device between the scattering device and thesecond application device. Instead, the still wet board is fed directlyinto the second application device after leaving the scattering device.

In a variant of the production line, the second application device forapplying the second resin layer is designed as a double applicationdevice, so that a corresponding resin layer is applied to the bottomside of the wood-based panel simultaneously or parallel to the secondresin layer on the top side.

In a further variant, the production line comprises at least one furtherapplication device arranged downstream of the first drying device in theprocessing direction for applying further resin layers to the top and/orbottom side of the carrier board and subsequent drying devices fordrying the further top and/or bottom resin layers.

In an embodiment, the present production line as a whole comprises asimple, single-sided applicator for applying the first resin layer tothe top side of the printed wood-based panel and six double applicatorsfor applying six further resin layers to the top and lower sides of thewood-based panel, wherein at least one drying device for drying the topand/or lower resin layer is provided behind each double applicator.

The production line also preferably comprises a short-cycle press (KTpress) arranged downstream of the last drying device in the processingdirection.

In a preferred embodiment, the production line for carrying out thepresent process comprises the following elements:

-   -   at least a first application device for applying a first layer        of resin, which may contain fibres, to the top surface of the        wood-based panel;    -   at least one device arranged downstream of the first application        device in the processing direction for scattering a        predetermined quantity of abrasion-resistant particles;    -   at least one second application device arranged behind the first        application device and scattering device in the processing        direction for applying a second resin layer to the top side of        the wood-based panel,    -   at least one first drying device arranged downstream of the        second application device in the processing direction for drying        the layered structure of first and second resin layers;    -   at least one third application device arranged downstream of the        first drying device in the direction of processing for applying        a third resin layer to the top side and/or a resin layer        parallel to the lower side of the carrier board,    -   at least one further drying device arranged behind the third        application device in the processing direction for drying the        third top and/or corresponding lower resin layer;    -   at least one fourth application device arranged downstream of        the further drying device in the processing direction for        applying a fourth resin layer to the top side, which may contain        glass beads, for example, and/or a resin layer parallel to the        bottom side of the carrier plate (without glass beads),    -   at least one drying device arranged behind the fourth        application device in the processing direction for drying the        third top and/or corresponding lower resin layer;    -   at least one fifth application device arranged downstream of the        drying device in the direction of processing for applying a        fifth resin layer, which may contain glass particles or glass        beads, for example, to the top side and/or a resin layer        parallel to the lower side of the support plate (without glass        beads or fibres);    -   at least one drying device arranged behind the fifth application        device in the processing direction for drying the fifth top        and/or corresponding lower resin layer;    -   at least one sixth application device arranged behind the drying        device in the processing direction for applying a sixth resin        layer to the top side and/or a resin layer parallel to the lower        side of the carrier plate    -   at least one drying device arranged behind the sixth application        device in the processing direction for drying the sixth top        and/or corresponding lower resin layer;    -   at least one seventh application device arranged behind the        drying device in the processing direction for applying a seventh        resin layer on the top side and/or a resin layer parallel to the        lower side of the carrier plate    -   at least one drying device arranged behind the seventh        application device in the processing direction for drying the        seventh top and/or corresponding lower resin layer;    -   at least one short-cycle press arranged downstream of the last        drying device in the processing direction.

The scattering device for the abrasion-resistant particles provided inthe present production line is suitable for scattering powder, granules,fibres and includes an oscillating brush system. The scattering deviceessentially consists of a hopper, a rotating structured roller and ascraper. The application rate of abrasion-resistant material isdetermined by the rotational speed of the roller. The scattering devicepreferably comprises a spiked roller.

In a version of the present production line, it is further provided thatthe at least one scattering device is surrounded by or arranged in atleast one booth provided with at least one means for removing dustoccurring in the booth. The means for removing the dusts can be in theform of a suction device or also as a device for blowing in air. Airinjection can be achieved by nozzles installed at the plate inlet andoutlet, which blow air into the booth. In addition, these can preventair movements from creating an inhomogeneous scattering curtain onabrasion-resistant material. The removal of dust from abrasion-resistantmaterial from the environment of the scattering device is advantageous,because apart from the obvious health risk for the workers working onthe production line, the fine dust from abrasion-resistant particles isalso deposited on other parts of the production line and leads toincreased wear and tear of these parts. The arrangement of thescattering device in a cabin therefore not only serves to reduce thedust pollution of the production line environment, but also preventspremature wear and tear.

The scattering device is preferably controlled by a light barrier,whereby the light barrier is arranged in the processing direction infront of the roller (scattering roller) provided below the scatteringdevice. The control of the scattering device by a light barrier isuseful because there are more or less large gaps between the individualwood-based panels.

In an embodiment of the present scattering device, at least one hopperis provided in front of the scattering roller for collecting excessabrasion-resistant particles (i.e. not scattered on the at least onewood-based panel, but rather, before the wood-based panel is moved in bymeans of the transport device under the scattering roller in front ofthe same falling abrasion-resistant particles).

In a further variant, the hopper is coupled with at least one conveyorand a screening device, whereby the excess abrasion-resistant materialcollected in the hopper is transported to the screening device via theconveyor. The screening meshes of the screening device correspond to thelargest grain of abrasion-resistant particulate material used (i.e.approx. 80-100 μm). In the screening device, dirt particles and lumpymaterial (such as lumpy resin or lumpy abrasion-resistant material) areseparated from the collected abrasion-resistant material and thescreened abrasion-resistant material can be returned (recycled) to thescattering device.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention is explained in more detail below with reference to thefigures in the drawings by means of an example of execution. Show it:

FIG. 1 is a schematic diagram of a wood-based panel production lineusing a conventional process; and

FIG. 2 is a schematic diagram of a production line of a wood-based panelusing the process according to the invention.

DESCRIPTION OF THE INVENTION

The conventional production line shown schematically in FIG. 1 comprisesan IR dryer 10, a single-sided applicator unit 1, and five doubleapplicator units 2, 3, 4, 5, 6 for simultaneous application of therespective resin layer to the top and bottom sides of the separatedprinted material boards, e.g. of printed HDF boards, as well as fourconvection dryers 1 a, 2 a, 3 a, 4 a, 5 a, 6 a each arranged behind theapplicator units in the processing direction.

Before the first resin application, the surface of the boards ispreheated by the IR dryer 10 to a temperature of approx. 45° C. Theresin is applied to the board surface via a rubberized roller in theapplicator unit. The excess resin is pumped back into the applicationtank, from where it is transported back to the rollers.

After the first application roller 1, a first scattering device 20 isprovided for evenly scattering the abrasion-resistant material such ascorundum on the first resin layer on the top of the HDF board. Theabrasion-resistant material used is corundum F200, which, according tothe FEPA standard, measures approximately 53-75 μm in diameter. Thescattering device 20 essentially consists of a storage hopper, arotating, structured spiked roller and a scraper. The application rateof the material is determined by the rotational speed of the scatteringroller. Depending on the required abrasion class of the product, between12-25 g/m² corundum is scatter onto the resin-coated plate (AC4(according to EN 13329)=20 g/m²). From the spiked roller, the corundumfalls at a distance of 5 cm onto the melamine resin treated panel. Sincethe first resin layer is still liquid at the time of scattering, theabrasion-resistant particles can sink into the resin layer. Below thepresent scattering device, in front of the scattering roller, there isat least one hopper (not shown) for collecting excess abrasion-resistantparticles (i.e. not scattered on the at least one wood-based panel, butrather, before the wood-based panel is moved by means of the transportdevice under the scattering roller, in front of the same fallingabrasion-resistant particles).

The first resin layer is then dried in the first convection dryer 1 a at150-250° C. for 20-50 s.

This is followed by a second double applicator 2 for applying a secondresin layer and a second convection dryer 2 a for drying the secondresin layer.

The third double coating unit 3 for the application of the third resinlayer can be followed by another scattering device 20 for theapplication of glass beads on the third resin layer followed by a thirdconvection dryer 3 a for drying the third resin layer. The scatteringdevice 20 for the glass beads is optional. The glass beads can also beapplied together with the third resin layer.

After application of the fourth to sixth resin layer in a fourth tosixth double application unit 4, 5, 6 and drying in a convection dryer 4a, 5 a, 6 a each, the layer structure is cured in a short-cycle press 7at a pressing temperature of 180-220° C. and a pressing time of 5 to 25seconds under a specific pressure of 35-55 kg/cm². The pressed sheetsare cooled and stored.

In the invention-related production line shown schematically in FIG. 2,the IR dryer 10 is removed or switched off. Removal of the IR dryer fromthe production line avoids the electrostatic charging of the boardsurface that would otherwise occur in the IR dryer, thus enabling theformation of a homogeneous scattering curtain of the corundum.

Furthermore, an additional double-sided applicator 1-1 is installedbehind the one-sided applicator 1 (grooved roller) and the scatteringdevice 20 in the processing direction, in which the panel coated withmelamine-formaldehyde resin and corundum is coated withmelamine-formaldehyde resin (approx. 20 g/m²). At the same time, theunattached corundum is removed in small quantities and accumulates inthe melamine resin liquor until saturation (about 10 wt. %). This lostportion of the corundum is now continuously re-applied to the board bythe roller application of the coating unit 1-1. By the secondapplication the corundum grains are covered with liquid resin or workedinto the overlay layer. This prevents the corundum from being removed inthe convection dryer due to the high air turbulence.

The coating unit 1-1 is followed by a convection dryer 1 a followed bythe other double coating units 2, 3, 4, 5, 6 for simultaneousapplication of the respective resin layer on the top and bottom side ofthe separated printed material sheets as well as the convection dryers 2a, 3 a, 4 a, 5 a, 6 a arranged behind the coating units in theprocessing direction.

The following advantages result from the conversion measures taken inthe production line of FIG. 2: Homogeneous scattering pattern; no lossof corundum in the dryer; reduction of the corundum consumption forrequired abrasion class; reduction of the dust load of the environmentand the obvious health burden of the employees; as well as corundum dustdeposits on plant parts of the production line; reduction of thecorundum deposit on the transport chains and thus saving of additionalmaterial costs by replacing the chains.

The invention claimed is:
 1. A method for producing anabrasion-resistant wood-based panel with a top side and a bottom side,wherein at least one decorative layer is provided on the top side in theform of a printed decoration, and wherein a protective layer of a notyet fully cured resin is applied to the decorative layer, comprising thesteps of: applying at least one first resin layer to the at least onedecorative layer on the upper surface of the wood-based panel, whereinthe wood-based panel provided with the protective layer and decorativelayer is not heated in a dryer before the application of the first resinlayer; even scattering of abrasion-resistant particles on the firstresin layer on the top side of the wood-based panel, wherein the firstresin layer provided with the abrasion-resistant particles on the uppersurface of the wood-based panel is not dried after application; applyingat least a second resin layer to the first wet resin layer provided withthe abrasion-resistant particles on the upper surface of the wood-basedpanel; subsequent drying of the assembly of first resin layer and secondresin layer on the upper surface of the wood-based panel in at least onedrying device; applying at least one further resin layer to the driedfirst and second resin layers provided with the abrasion-resistantparticles on the upper surface of the wood-based panel and then dryingafter the respective application; and, pressing the layer structurefollowing the last drying step in a short-cycle press.
 2. The methodaccording to claim 1, wherein the resin layers are based on aqueousformaldehyde-containing resins, such as melamine-formaldehyde resin,urea-formaldehyde resin or melamine-urea-formaldehyde resin.
 3. Themethod according to claim 1, wherein the first resin layer is applied inan amount between 10 to 100 g/m².
 4. The method according to claim 1,wherein the first resin layer is applied in an amount between 40 to 80g/m².
 5. The method according to claim 1, wherein the first resin layeris applied in amount between 45 to 60 g/m².
 6. The method according toclaim 1, wherein the amount of scattered abrasion-resistant particles is10 to 50 g/m².
 7. The method according to claim 1, wherein the amount ofscattered abrasion-resistant particles is 10 to 30 g/m².
 8. The methodaccording to claim 1, wherein the amount of scattered abrasion-resistantparticles is 15 to 25 g/m².
 9. The method according claim 1, wherein thesecond resin layer applied to the upper surface of the wood-based panelis applied in an amount between 10 to 50 g/m².
 10. The method accordingto claim 1, wherein the second resin layer applied to the upper surfaceof the wood-based panel is applied in an amount between 20 to 30 g/m².11. The method according to claim 1, wherein the second resin layerapplied to the upper surface of the wood-based panel is applied in anamount between 20 to 25 g/m².
 12. The method according to claim 1,wherein a third, fourth, fifth and sixth resin layer is applied to thedried first and second resin layer provided with the abrasion-resistantparticles on the upper surface of the wood-based panel, and each isdried after application.
 13. The method according to claim 12, whereinthe at least one of the third, fourth, fifth and sixth resin layercomprises glass beads or fibers.
 14. The method according to claim 13,wherein the glass beads or fibers comprise wood fibers or cellulosefibers.
 15. The method according to claim 1, wherein an at least oneresin layer is applied to the bottom surface of the wood-based paneltogether with the second resin layer to be applied to the top surface ofthe wood-based panel.
 16. The method according to claim 1, wherein theat least one wood-based panel is a medium density fiber (MDF), highdensity fiber (HDF) or rough chipboard (OSB) or plywood panel and/or awood-plastic panel.
 17. A production line for carrying out a processaccording to claim 1, comprising: at least one first applicator devicefor applying a first resin layer to the upper surface of the wood-basedpanel, wherein no active drying device is provided upstream of the firstapplicator device; and wherein the at least one first applicator isdesigned as a single-sided applicator with a grooved roller; at leastone device for scattering a predetermined quantity of abrasion-resistantparticles, arranged downstream of the first applicator device in theprocessing direction; at least one second applicator device arrangeddownstream of the first applicator device and spreader device forapplying a second resin layer to the upper surface of the wood-basedpanel, wherein no drying device is provided between the spreading deviceand the second application device; at least one first drying devicearranged downstream of the second application device in the processingdirection for drying the layer structure of first and second resinlayers; at least one further application device arranged downstream ofthe first drying device in the processing direction for applying afurther resin layer to the upper side and/or lower side of the carrierplate and subsequent drying device for drying the further upper and/orlower resin layer; and, a short-cycle press (KT press) arrangeddownstream of the last drying device.
 18. The production line accordingto claim 17, wherein the second applicator for applying the second resinlayer is formed as a double applicator, so that a resin layer is appliedto the underside of the wood-based panel simultaneously with the secondresin layer on the upper side.
 19. A method of producing a panel, themethod comprising: providing a panel comprising wood and having a topside and a bottom side, wherein at least one decorative layer isprovided on the top side, and wherein a protective layer of a partiallybut not yet completely cured resin is applied to the decorative layer;applying a first resin layer to the protective layer on the top side ofthe panel, wherein the provided panel including the decorative layer andthe protective layer is not heated in a dryer before the application ofthe first resin layer; scattering abrasion-resistant particles on thefirst resin layer on the top side of the panel, wherein the first resinlayer on the top side of the panel provided with the abrasion-resistantparticles is not dried after application; applying a second layer ofresin to the first resin layer on the top side of the panel; andsubsequently drying the structure consisting of the first resin layerand the second resin layer on the top side of the panel in at least onedrying device, wherein the abrasion-resistant particles comprise one ormore of corundum, boron carbide, silicon dioxide, and silicon carbide,and wherein the second resin layer is applied using a roller applicatorand at least a portion of the abrasion-resistant particles scattered onthe first resin layer and not fixed to or penetrated into the firstresin layer are taken up by the roller applicator and entrained in theresin applied as the second resin layer such that, after drying, boththe first and second resin layers contain the abrasion-resistantparticles, applying at least one further resin layer to the dried firstand second resin layers provided with the abrasion-resistant particleson the upper surface of the wood-based panel and then drying after therespective application; and, pressing of the layer structure followingthe last drying step in a short-cycle press.